Pipeline optical flow meter

ABSTRACT

The present invention provides an optical device for the measurement of flow rates of fluid through a pipe. The device broadly comprises a narrow frequency light source, an optical delivery system, a collector for light scattered from particles in the fluid, and a photo detector. In a preferred embodiment, the optical delivery system and the collector are contained within the pipe.

RELATED APPLICATIONS

This is a continuing application of U.S. patent application Ser. No.09/065,364, filed Apr. 23, 1998 now U.S. Pat. No. 6,128,072.

FIELD OF THE INVENTION

This invention relates to an optical flow meter system for measuring theflow of fluid in a pipeline.

BACKGROUND OF THE INVENTION

One of the requirements for the successful operation of any pipeline isthe capability to accurately measure flow rates at many locations withinthe system. A number of different flow meters are currently commerciallyavailable for this purpose, each having its own advantages andlimitations. Existing meters can be classified into three main types,namely obstruction meters, kinematic meters and non-intrusive meters.

Obstruction meters determine flow rate in an indirect fashion byintroducing a physical obstruction directly into the flow and measuringthe influence of the obstruction. For example the pressure drop across aflow restriction is often measured and correlated with the flow rate.Examples of this approach include orifice meters, venturi meters andcritical flow nozzles [ref. Experimental Methods For Engineers, FourthEdition, McGraw-Hill Book Company, J. P. Holman and W. J. Gajda, Jr.,Chapter Seven]. Another example of an obstruction meter is the vortexmeter, in which the obstruction causes vortex shedding. The sheddingfrequency is determined by means of strain sensors, thermal sensors, orpressure sensors. The shedding frequency increases with flow rate.

Obstruction meters extract energy from the flow and are thereforeinherently inefficient because additional pumping capacity is requiredto overcome the induced pressure drop. The physical obstruction alsoprevents the use of pipeline-pigs for maintenance and diagnostics.Component wear can cause a shift in the discharge coefficient orshedding frequency, and therefore regular maintenance of these devicesis required. Pressure or load transducers are normally mounted next tothe obstruction, and therefore local power is required. For pipelinestransporting flammable or explosive fluids, appropriate explosion-proofenclosures are required for these transducers. Finally, these metershave a limited turndown ratio owing to the nonlinear relationshipbetween flow rate and pressure drop.

Kinematic type meters determine the flow rate by directly sensing theactual velocity using a turbine blade assembly that rotateskinematically with the flow. The rotational speed of the turbine ismeasured using a frequency pickup and is empirically related to the flowrate using an experimentally determined coefficient. These metersprovide an output that is approximately proportional to volumetric flowrate and substantially independent of density. The primary disadvantagesof this class of meter are the presence of moving parts, the obstructionto flow, the need for calibration, the requirement of electrical powerand the physical size.

The third class of meter relies on non-intrusive methods to determineflow rate. The ultrasonic flow meter is the only meter in this categorythat has been commercially developed for use in high pressure naturalgas pipelines. The operating principle is to compare the upstream anddownstream times of flight of an acoustic pulse from one transducer toanother, which are located near the inside surface of the pipe. The flowis unrestricted and therefore these devices do not produce anysignificant pressure drop. However, these devices require a relativelylong installation length, are limited to larger pipe sizes, can sufferfrom acoustic noise and are sensitive to swirl in the flow.

Each of the meters described above has deficiencies in one or more ofthe following areas:

Size: The device should be small enough to permit installation inlimited space.

Low Maintenance: Moving parts should be avoided to reduce maintenancerequirements.

Power Supply: The device should not require electrical power at themeter.

High Turn-Down: The device should provide accurate measurement of flowrates over a 50:1 turndown ratio.

Optical flow measurement offers the potential to address all of theabove-noted deficiencies of “prior art” meters.

For example, flow rate may be determined by measuring the velocity ofmicron-sized particles suspended in a flow field. This is accomplishedby determining the time-of-flight of these particles as they movebetween two discrete regions illuminated by laser light. This basicconcept was proved by D. H. Thomson [“A Tracer Particle Fluid VelocityMeter Incorporating a Laser”, Jour. of Sci. Inst. (J. Phys. E.) Series2, Vol. 1, 929-932 (1968)] using a large gas laser, Kosters prism, twoconvex lenses, an imaging lens and a photomultiplier.

The time-of-flight concept has been applied to a device to measure theair speed of an aircraft (as described in U.S. Pat. Nos. (“USP”)4,887,213; 5,046,840 and 5,313,263). Three pairs of laser sheets areprojected into free air through a window located in the side of theaircraft fuselage. Small particles in the atmosphere passing through thelaser sheets produce scattered light that is collected from each pair oflaser sheets. This light is imaged onto photodiodes and the resultingsignal is processed to determine the velocity vector. However, thisprior device is designed for the aviation environment and cannot be usedin pipeline applications.

Optical techniques have also been employed by numerous investigators tomake measurements in laboratory environments, particularly inwind-tunnels and turbo machinery, notably R. Scholdl [“A Laser-Two-Focus(L2F) Velocimeter for Automatic Flow Vector Measurement in RotatingComponents of Turbomachines”, Transaction of the ASME, Vol. 102, p 412,December, 1980]. Additionally, UK Patent 2,295,670 describes such aconfiguration in which laser light from an argon ion laser is split by aRochon prism, made parallel by a lens and then focused into two focusedspots. Scattered light produced by particles passing through the twospots is imaged onto two photoelectric converters. Velocity isdetermined on the basis of the transit time of the particles passingbetween the two spots. U.S. Pat. No. 4,125,778 claims a similar deviceexcept that the relative position of the two spots could be rotatedusing an optical component.

A variation on the time of flight principle using laser diode arrays(i.e. multiple lasers in a monolithic device) was applied by M. Azzazy[“GRI Report 89/0201 Development of an Optical Volumetric Flow Meter”(1989)] to measure the velocity profile inside a high pressure naturalgas pipe through a glass window. In this case, the image of the diodearray produced a series of spots in space and the light scattered bysmall particles was collected and converted to an electrical signal. Thefrequency content of the signal and the spacing of the spots of lightwere then used to determine the flow velocity. Measurements wereobtained at a series of locations by mechanically translating themeasurement system which was located outside the pipe. The bulky size ofthe system, in combination with the large optical window, rendered itimpractical for broad commercial applications.

Improvements to this system (i.e. using laser diode arrays) aredescribed in U.S. Pat. No. 5,701,172 issued Dec. 23, 1997 assigned toGas Research institute. The patent also describes the system used incombination with a hologram and a window in a pipe to produce multiplemeasurement locations along one pipe diameter within a pipeline. All ofthe illustrations and examples of the patent are limited to the casewhere the optical source and lens are external to the pipeline.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a diagram of a commercial orifice meter fitting.

FIG. 2 is a schematic diagram of an optical meter according to thisinvention.

FIG. 3 illustrates the steps in processing the data from the device.

FIG. 4 is a schematic optical layout of a preferred embodiment of thisinvention with specific components.

FIG. 5 is a schematic diagram of a preferred form of a collection lens.

FIG. 6 is a diagram of a rigid plate which fits into an orifice meterand houses the optical system.

FIG. 7 is a plot of experimental results of the device.

SUMMARY OF THE INVENTION

The present invention provides an optical device for generating a signalwhich contains information which may be used to describe the fluid flowon the basis of the motion of suspended particles contained in a fluidflowing through a pipeline, said device comprising: a narrow frequencylight source; one or more optical delivery systems; one or morecollectors which collect light scattered by particles in the flow; andone or more photo detectors. In a preferred embodiment, the opticaldelivery system(s) and collector(s) are contained within the pipeline.

That is, the device of the present invention generates signals based onthe light scattered by particles flowing through a pipeline.

The present invention further provides an optical device for generatinginformation to determine the flow rate of a fluid within a pipecomprising in cooperating arrangement an orifice fitting having mountedtherein a rigid plate. The rigid plate holds at least one opticaldelivery system providing at least two parallel beams of light and acollector receiving scattered light from particles in the fluid movingthrough the pipeline.

The optical device of this invention contains two optical sub-systems,namely a “delivery” system and a “collection” system. The deliverysystem is designed to provide a parallel pair of light beams (preferablylaser beams), separated by a known distance, through the center of apipeline. The optical delivery system may comprise one or more of: acollimator, a light splitter and a focussing lens. The two beams arepreferably perpendicular to the axis of the pipe, with one light (laser)beam located upstream of the other. The light beams are conditioned(focused) such that they are most intense at the location within thepipe that the measurement is to be made. Small particles suspended inthe natural gas flow pass through the two beams, producing brief pulsesof scattered light. These pulses of light are received by the secondoptical sub-system (the “collection” system) which collects scatteredlight from a small region of interest. The optical sub-systems arealigned such that the optical collection region is coincident with themost intense regions of the light beams, which defines a localizedmeasurement volume.

The optical flow meter is invested into the pipeline either via anexisting meter fitting or a new fitting. Most preferably, this isachieved by encasing critical elements of the optical flow meter in ahousing which is adapted to an existing meter fitting.

Thus, the present invention enables the use of an optical system tomeasure the flow of fluid in a pipeline, especially the flow of naturalgas in a high pressure pipeline.

The present invention further provides a process for measuring the flowrate of a fluid having entrained suspended particles through a pipecomprising comparing the timing of light scattering events from at leastone light sheet in said pipe to the light scattering events from atleast one other light sheet in said pipe using one of the devicesdescribed above and comparing the events from both light sheets togenerate a histogram (called a corrologram) which has a characteristicpeak corresponding to the flow rate.

The optical flow meter described herein is a robust device which may beused in a remote environment.

DETAILED DESCRIPTION

As used in this specification a narrow frequency light source means asystem that provides essentially monochromatic light having a wavelengthpreferably within a range of 50 nanometers (nm), most preferably withina range of 10 nm.

The measurement volume is the location or locations where the sheet oflight or beam of light is focused within the interior of the pipeline todetect particles passing through such location(s); particles scatterlight from the optical delivery system and scattered light is gatheredby the collector.

In accordance with the present invention, the input for and output fromthe optical delivery system and collector communicate externally fromthe pipeline preferably via an optical transmission path, mostpreferably an optical fiber(s). The optical fiber(s) may be continuousor they may include appropriate coupling devices such as those sold byAT&T under the trademark ST connectors. However other means forproviding input and receiving output from the device of the presentinvention would occur to those skilled in the art.

Preferred embodiments of the invention will now be described in detailwith reference to the accompanying drawings.

The flow meter of the present invention may be installed in thepipeline, for example between adjacent flanges. However, such aninstallation is not easily removed for maintenance or servicing. In apreferred embodiment of the present invention the device is installed ina removable cooperating plate and fitting such as an orifice platecarrier and fitting. FIG. 1 shows a cross section of a typicalcommercial orifice fitting.

The standard orifice meter in the natural gas industry such as thatshown in FIG. 1 consists of a meter body 101 that permits the orificeplate 102 to be inserted into or removed from a high pressure pipe 103.The orifice plate 102, which is a round steel plate with a hole in thecenter, is fitted with a thick rubber gasket 104 around itscircumference. This gasket provides a seal when the plate is in use toensure that all of the flow passes through the central hole 105. Thegasket and orifice plate fit into a larger rectangular “plate carrier”106. The plate carrier is inserted into the body of the meter 101through a closable opening 107 and holds the orifice plate 102 in place.The housing of the meter can generally be of two types: those that allowthe plate to be inserted and removed while the system is under pressure;and those that require that the pipe be depressurized before the orificeplate can be removed.

FIG. 2 shows a preferred configuration of the optical flow meter. Anarrow frequency light source 201 (preferably a laser) is located atsome distance from the actual meter housing, and the energy emitted bythe laser is transmitted to the meter via a single mode polarizationmaintaining optical fiber link 202 (i.e. an optical fiber). The opticalfiber enters the body of the meter through a high-pressure fitting 203accommodating both the transmission fiber and multi-mode receivingoptical fiber 209. The transmission optical fiber terminates in acollimator 204. The beam exiting the collimator then passes through abeam splitting prism 205 to generate two beams, followed by a focusinglens 206 which produces parallel light beams 207 focused within the pipetypically at or adjacent to the centerline of the pipe for a singlepoint measurement using two sheets of light. As shown in FIG. 2 theparallel light beams are focused, that is they narrow to a waist at orwithin the measurement volume (and they diverge on each side of themeasurement volume). This results in an intensely illuminated region atthe light beam waist preferably a high intensity sheet of light (but itcould also be a spot of light). Note that for any velocity measurementat a specific location at least two closely spaced sheets of light arerequired. For measurements at more than one location the measurementvolumes may be located at different positions within the cross-sectionof the pipe. Light scattered by small particles (micron and sub-micronsized particles) passing through the beam in the measurement volume, iscollected by a collection lens 208 (which collection lens 208 ispreferably a refractive doublet or diffractive/refractive doublet) thatfocuses the collected light onto the end of a receiving optical fiber209. The receiving optical fiber 209 transmits the scattered lightpulses back to a photo detector 210 (avalanche photodiode(s) or photomultiplier tube(s)) located near the laser. The electrical output fromthe photo-detector is analyzed in a signal processor unit 211 thatcorrelates the optical pulses and determines flow rate at themeasurement volume. It will be appreciated by those skilled in the artthat the small particles referred to above are typically found in fluidflows (if an ultra clean fluid is being measured, it may be necessary toadd such particles).

Each particle that passes through the pair of light beams (or sheets)emits two pulses of scattered light, separated by an amount of time Δt.By measuring Δt, and knowing the physical spacing between the two beams(S), it is possible to determine the average velocity from therelationship U_(avg)=S/Δt. Correlation techniques are used to analyzestreams of pulses produced by numerous particles passing through thebeams over a prescribed period of time. This technique eliminates theambiguity that results from overlapping pulse pairs, plus it minimizesthe influence of single pulse events which occur when a particle passesthrough only one of the two beams. One method of correlating high datarates is outlined in U.S. Pat. No. 4,887,213.

FIG. 3 shows a preferred method of calculating the velocity of a fluid.The figure consists of three components: a plot of output signal versustime (a); the process of digitizing an individual pulse (output) (b);and a histogram (corrologram) of transit velocities (c). Therelationship between these three aspects of the velocity calculation aredescribed below.

The signals, such as those shown in FIG. 3(a), are generated by thedevice, with a characteristic lag between events (detection of scatteredlight) on the upstream and downstream channels (e.g. photo detectors).Each of these pulses is digitized when a certain threshold 301 (e.g.exceeding the background noise) is exceeded as shown in (b). The timethat the pulse occurred has to be identified for each pulse. The time ofoccurrence (temporal centroid) is determined, either by midpoint betweenthe time when the signal exceeds the threshold 302 and when the signalfalls below the threshold 303, or by a weighted average of the digitizedpulse shape, as shown in FIG. 3(b). The time and amplitude of the pulsesare stored for later reference. Each pulse that occurred on thedownstream channel (e.g. 305) is compared to previous pulses thatoccurred on the upstream channel 306 (limited by a time which is equalto or greater than the transit time for the minimum detectable velocity)to generate a series of potential transit times Δt for each down streampulse. Each transit time is converted into a possible transit velocityby dividing the beam spacing by the transit time. This series ofpotential transit velocities are accumulated and stored in a histogramcalled a corrologram, such as that shown in FIG. 3(c). The corrologramshows the number of possible transit velocities that lie in a narrowrange called a “bin”. The number of events in each bin is represented bythe bars in FIG. 3(c). The average transit velocity can be determined bythe average of the velocities in the most populated bin (and theappropriate number of neighboring bins).

Schemes that weight the importance of the transit velocity based on thesimilarity of the amplitudes of the upstream and downstream pulses maybe used to increase the accuracy. The premise in such schemes is thatpairs of pulses caused by the same particle should be of similaramplitude, and that since the objective is to determine which pairscorrespond to one particle passing through both sheets, the pairs withsimilar amplitude should be weighted more heavily.

This method can be generalized to the case where both pulses aregenerated by the same detector. In this case all pulses are consideredas possible upstream and downstream pulses (since the upstream anddownstream information is indistinguishable), and the corrologram stillshows a characteristic transit velocity.

Broadly the present invention seeks to provide a process for determiningthe velocity of a fluid moving through a pipe comprising converting theelectrical signals generated by a device according to the inventioncomprising:

(a) digitizing each pulse of the detector output signal caused bycollected light scattered from a particle passing through a light sheetexceeding a threshold above the ambient noise and determining itstemporal centroid;

(b) comparing the temporal centroid of each pulse that could haveoriginated on the downstream sheet of light to the time of the pulsesthat could have occurred on the upstream beam in the recent past toobtain a possible transit time of a particle from one sheet of light toanother;

(c) converting each transit time to a transit velocity, by dividing thedistance between the sheets by the transit time and recording thetransit velocities in a corrologram;

(d) identifying the peak in the corrologram generated over a finite timeperiod by the large number of transit velocities clustered at a specificvelocity;

(e) averaging transit velocities within that cluster in the corrologram.

The light source and the photodiode are external to the pipe; however apreferred embodiment of the invention requires that the optical lensesbe located within the pipe. The advantage of placing the optical lensesinside the pipe is that for high pressure applications, windows are notrequired, and the optical system is confined to the inside of the pipethereby reducing the safety issues associated with exposed laser lightsources. The use of optical fiber also means that the electronics andprocessing system may be located many hundreds of meters from the actualmeasurement location. Additional advantages of the optical device ofthis invention include: (a) it does not introduce a pressure drop in thepipeline; (b) it may require less than five centimeters of pipe lengthfor installation; and (c) it does not have moving parts that can wearover time. The device is fully compatible with a range of pipelineenvironments including high-pressure natural gas. Furthermore, noelectrical supply is required at the meter location.

The optical device described above may be constructed using a number ofalternative components and each of these individual configurations maybe installed in various mechanical housings. One preferred embodimentdescribed below is tailored to be installed in a standard orifice platecarrier housing used in natural gas pipeline systems. This bodiment isparticularly attractive to those users who have many orifice fittingsalready installed in the field.

FIG. 4 shows the optical components used in a preferred design of aplate that replaces the plate carrier, and Table 1 provides a detaileddescription of each component.

TABLE 1 Optical Components in FIG. 4 Item # Description SupplierModel/Part Number 401 150 mW Laser (830 SDL SDL-5421-G1 nm) 402 Lasercurrent driver Seastar LD 1000 404 Laser/fiber coupler OZ OpticsLDPC-02-830-5/125- P-40 407 High pressure pass- PAVE PT-SS-150-FOSM-through fitting Technology Inc. 408 FC Polarization- OZ Opticsmaintaining connector 409 Collimator with vent OZ OpticsLPC-04-830-5/125-P- hole in housing to 0.86-3.0GR-40-3-3A- equalizepressure 0.6-SP 410 Wollaston prism Karl Lambrecht WQ6.35-05-V830 or(0.5° or .75°) Corp. WQ6.35-075-V830 V coated for 830 nm 411 CylindricalLens cut Melles Griot 01 LCP 001 or down to 6.35 mm 01 LCP 005 sq. 413Cemented doublet NOVA designed, 15 mm diameter built by Lumonics Optics414 Collection fibers Thor Labs FG-200-LCR (multimode) (3M product) NA =0.22, low OH 415 SMA connectors Thor Labs 10230A 416 High pressure pass-PAVE PT-SS-150-FG200- through fitting Technology Inc. 417 SiliconeAvalanche EG & G C30657-010-QC-06 Photo Diode (APD) Optoelectronics withtransimpedance amplifier

Preferred Optical Delivery System

Light energy is provided by a 150 mW near-infrared diode laser 401 (suchas that sold by SDL Inc. (San Jose, Calif.)), driven by a laser currentsupply (402) such as that sold by Seastar Optics Inc. (Sidney, BC) thatis connected to diode laser 401 by an electrical cable 403. The laserdiode is directly pigtailed to polarization-maintaining fiber (405)using laser to fiber coupler (404), such as that sold by OZ Optics Ltd.(Carp, ON). The fiber enters the high pressure housing (406) through apressure fitting (407) such as those sold by PAVE Technology Co. Inc.(Dayton, Ohio). For convenience an FC polarization maintaining connector(408) is located on either side of the bulkhead such that the individualassemblies can be easily separated. The light energy exiting the fiber405 is collimated into a uniform laser beam using a collimator 409(which uses a 0.25 pitch GRIN lens) such as those sold by Oz Optics Ltd.The collimator has a small vent hole to prevent damage to the opticalfitting under pressure. The beam is then split into two beams using aWollaston prism 410 such as those sold by Karl Lambrecht Corp. (ChicagoIll.). If required by space restrictions, the two beams may reflect offa planar mirror towards a cylindrical lens 411, otherwise the two beamsproject directly to the cylindrical lens 411. The cylindrical lensrefracts the beams such that they become parallel. The cylindrical lensalso focuses each of the beams such that two high intensity laser sheetsare produced in the measurement volume 412. This may be at a distance ofapproximately 50 mm from the lens.

Preferred Optical Collection System

Scattered light, caused by particles passing through the waist regionsof the two sheets, is collected and focused onto the ends of two 200micron multi-mode optical fibers 414 by a specialized collection lens413. This lens is preferably designed to prevent variations inrefractive index from altering the focal length of the collectionoptics. (A detailed description of a novel collection lens is providedin the next section.) The multi-mode optical fibers pass through asecond pressure fitting 416 as described above with SMA 905 connectors415 on either side for easy removal. The collected light energy istransmitted by the multi-mode fibers 414 to a pair of avalanchephotodiodes with built-in transimpedance amplifiers 417 such as thosemanufactured by EG&G Canada Ltd., Optoelectronics Division. The voltageoutputs from the photodiodes are digitized and processed to determineparticle velocity.

Lens Operation in High Pressure Environments

Typical imaging systems use a lens which refracts light passing throughit to form an image of the object at the desired location. Refractionoccurs when light rays pass from the external medium (usually air) tothe lens material (usually glass) or vice versa. Refraction, or theamount of bending of the light rays depends on the index of refractionof the two media in contact, and is governed by Snell's Law. Snell's Lawstates that n₁ sin θ₁=n₂ sin θ₂, where n is the index of refraction ofthe medium, and θ is the angle that the ray makes with a normal to thesurface, and the indices 1 and 2 refer to the two media in contact.

If the index of refraction of the surrounding medium can changesignificantly, then the performance of the optical system will depend onthe external medium. For instance, the surrounding medium could be airat atmospheric pressure, a high pressure gas, or a liquid.

To successfully image particles inside a high pressure natural gasenvironment such as a pipeline, the optical system must work correctlyat the full range of pipeline pressures without adjustment. Forpractical purposes the system should also work at atmospheric conditionsto facilitate the initial setup and testing. Any mechanical adjustmentof optical alignment to compensate for the changes in refractive indexof the gas in the pipe would normally be very difficult to performinside the pressure-containing vessel and would have to be donecontinuously to account for changes in gas pressure and temperature andcomposition.

Collection Lens

The preferred collection lens images a particle to an apertureindependently of the index of refraction of the surrounding medium. Alight detector is located behind the aperture. The collection lensshould also meet the following constraints. The object and image shouldbe small relative to the lens. The object and image should be near theoptical axis of the lens. The object (e.g. the particulate in themeasurement volume) and its image should be at specifically definedlocations. To achieve lens performance that is independent of the indexof refraction of the surrounding medium, the position of the object isrestricted. Preferably the wavelength of light is fixed.

This performance may be achieved in a lens having concave first and lastsurfaces which are defined by spheres centered at the object and imagelocations respectively. All refraction of the light as it passes fromthe object to the image occurs internal to the lens. The lens has theappropriate light refraction to be consistent with the object and imagelocation. If the above criteria are met the lens will ensure that allrays from the object enter the first surface at a perpendicular andleave the last surface at a perpendicular, hence there will be norefraction at the surface in contact with the surrounding medium. Thelight from the image is directed to the detector or an optical fiberfeeding the detector.

The internal refraction of light can be achieved by a number of methodsincluding using: a material with a radial gradient in the index ofrefraction; a sealed air or gas space between the elements; a sealedliquid between the elements; a cemented doublet with two materials ofdiffering index of refraction; a cemented lens of more than twoelements; or a combination of the above.

The preferred embodiment of the collection lens consists of a cementeddoublet with two different materials with a large difference inrefractive index and high transmission at the wavelength(s) of light ofinterest. FIG. 5 shows the preferred lens 501 comprising a low index ofrefraction material 502 and a high index of refraction material 503. Thehigh and low index of refraction materials are cemented together over acontinuous surface 505 which may or may not be spherical.

The surface of the low index of refraction material facing the object504 (e.g. the particle scattering light) has a radius of curvature sothat light scattered by particles strikes the surface facing theparticles normally (at right angles). The external surface of the highindex of refraction material 503 faces the detector 506 (or opticalfiber leading to the detector) and has a radius of curvature so thatpoint 506 is at the center of a sphere defined by the radius ofcurvature.

The preferred collector lens eliminates sensitivities to the index ofrefraction of the surrounding fluid which will vary with temperature,pressure, and composition of the fluid.

There are computer programs available which will perform thecalculations to define the curvature of the doublet internal surfaces505 based on the indices of refraction of each component. One suchcomputer program is available under the trademark ZEMAX, sold by FocusSoftware of Tucson Ariz.

In a further embodiment of the present invention the cylindrical lens inthe delivery system is made insensitive to the index of refraction ofthe surrounding fluid by use of a cylindrical doublet using theprinciples described above. That is, the light strikes at normalincidence (90°) at any lens surface where the surrounding fluid is incontact with the lens.

Mechanical Design

In a preferred embodiment, the optical device of the present inventionis constructed such that it is mounted within a rigid plate andinstalled within a standard orifice fitting. Such a plate is illustratedin FIG. 6 showing the location of the principal components. The platecarrier and orifice plate is replaced by a single plate 601 with acentral hole 602 that preferably matches the inside diameter of thepipe. The optics of this invention are mounted in the plate 601 itselfand the plate would be raised and lowered in the same manner as astandard plate carrier. The plate therefore provides a rigid,pre-aligned assembly that can be easily inserted into the orificefitting. The optical fiber which delivers light from the light sourcefits in a slot 603 in the plate. The fiber terminates at the collimator604 which is held in a slot 606 by supports 605 which are designed to beadjustably positioned in the slot 606. The light leaving the collimator604 strikes the Wollaston prism 607 and is split into two beams. Thebeams of light reflect off a mirror 608 and are focussed and madeparallel by a cylindrical lens 609 which is held in place by adjustablesupports 605. The beams are focussed to a waist at the center of thepipe where the (small) measurement volume 610 is located. Lightscattered by particles passing through the measurement volume 610 iscollected by a refractive doublet 611 which is insensitive to the indexof refraction of the surrounding fluid. The light is focussed to animage point 612 and enters one of two optical fibers leading to thedetectors. One fiber receives the image of the upstream sheet of lightand the other fiber receives the image of the downstream sheet of light.

The angle between the optical delivery system and the collector may beany angle, including 180°, or direct backscatter. However, aparticularly preferred angle is in the range of 5° to 25° from forwardscatter. The orifice fitting has several threaded holes in the body forpressure measurement and optional crank handle locations. These holesprovide locations for the high pressure fiber optic pass-throughfittings to be installed, thereby providing the necessary opticalcommunication between the internal and external components. Installationof the optical system within the orifice fitting has the advantages ofproviding highly rangeable measurement with virtually zero pressuredrop, without the expense and time of having to modify the existingpiping.

Flow Measurement Based on Velocity Data

When the velocity distribution in the pipe is well conditioned (forexample, in fully developed flow, or downstream of a flow conditioner),a single point centerline measurement is generally sufficient to achievean accurate measurement of volumetric flow rate. In this case the flowrate is determined by the product of the centerline velocity and acoefficient which ranges from between about 0.5 for fully laminar flowand about 0.86 for fully turbulent flow. The value of the coefficient isa function of the pipe Reynolds number and pipe roughness and can bedetermined from an empirical expression [ref. White, Frank M., “FluidMechanics”, 2nd ed. McGraw Hill 1986, p. 310]. When a flow conditioneris located upstream of the measurement system a geometry specificcorrelation must be used to determine the average velocity from themeasured centerline value.

When the approaching flow is not fully developed, or is poorlyconditioned, it is impossible to obtain an accurate measurement ofvolumetric flow rate on the basis of the centerline velocity alone. Ifmeasurements are made at sufficient locations within the pipe however,an accurate estimate of the flow rate can be made. Techniques to selectthe most appropriate measurement locations are outlined by F. C. Kinghomand A. McHugh “An International Comparison of Integration Techniques forTraverse Methods in Flow Measurement”, La Houille Blanche, No. 1, 1977and S. Frank, C. Heilmann and H. E. Siekmann, “Point-velocity Methodsfor Flow-Rate Measurements in Asymmetric Pipe Flows”, Flow Meas.Instrum., Vol. 7, No. 34, pp. 201-209, 1996. For example, using a totalof five data points it is possible to reduce the error for a moderatelyill-conditioned profile to less than 1.0%-2%, and for veryill-conditioned profiles the errors are generally less than 4%.

In a preferred embodiment of the invention the total flow rate throughthe pipe is determined using measurements at five points located in thepipe cross-section. Most preferably, these five points are located,according to the locations specified by Frank, Heilmann and Siekmann.One point is located at the center of the pipe, and the other fourpoints are located a distance of 0.762R from the center, where R is theradius of the pipe. Further, these four points are spaced equally aroundthe circumference of a circle with radius 0.762R. These locations aredesignated subscripts: 0 for the center point, and 1, 2, 3 and 4 for theremaining four points. A ratio a_(u) is determined according to thefollowing formula:$a_{u} = \frac{\frac{1}{n}{\sum\limits_{j = 1}^{n}\quad v_{j}}}{v_{0}}$

where v is the velocity at each location designated by the subscript.The value of a_(u) is used to select a center-point correction factora_(v) from the following table:

Criteria Center-point factor, a_(v) a_(u) ≧ 0.86 0.8941 0.86 > a_(u) ≧0.83 0.8526 0.83 > a_(u) ≧ 0.80 0.8167 0.80 > a_(u) 0.7575

The average flow rate U (i.e. the volumetric flow rate divided by thepipe cross sectional area) can be determined from:$U = {\frac{1}{6}\left( {v_{1} + v_{2} + v_{3} + v_{4} + {2a_{v}v_{0}}} \right)}$

The Optical Flow Meter described here can easily be extended to permitthe measurement of velocities at multiple points, and therefore flowrate measurements can be obtained with the proposed device inill-conditioned flows.

Multiple measurement volumes may be accomplished mechanically bymultiple implementations of the single point techniques described above(i.e. multiple sets of delivery and collection systems). However,optical systems may also be used to generate multiple measurementvolumes using a single optical element. This may be done for exampleusing a prerecorded hologram or by using a manufactured diffractiveoptical element (e.g. a diffraction grating). Diffractive or holographicoptical elements may also be used to collect light from the multiplemeasurement volumes.

The optical flow meter of the present invention is illustrated by thefollowing non-limiting example.

Experimental Results

The accuracy of a prototype (as described relative to FIG. 6 above) wastested in a high pressure (5500 kPa) natural gas facility. A calibratedNPS 4 orifice meter that was used in the development of the revised(1998) API (American Petroleum Institute) orifice standard was used asthe reference. The accuracy of this mass flow rate measurement isconsidered to be within ±0.3%.

A NOVA 50E perforated plate flow conditioner was located 42 D (pipediameters) upstream of the device to ensure a known and repeatable fullydeveloped flow profile. Extensive measurements taken using pitot tubesand hot film anemometers have shown that the peak velocity (centerline)of a fully developed profile under the test conditions is 1.16 times theaverage velocity. Development of the NOVA 50E flow conditioner isexplained in reference: Karnik, U., “A compact orifice meter/flowconditioner package”, 3rd International Symposium on Fluid FlowMeasurement, Mar. 20-22, 1995.

In these tests the average velocity was varied between 10 and 25 m/sec.The centerline velocity measurement obtained with the optical flow meterwas compared to a predicted centerline velocity based on the orificemeter data, the shape of the velocity profile that is produced by theflow conditioner, and the temperature, pressure and gas compositionmeasurements. Temperature and static pressure readings were taken at themeasurement location to allow accurate determination of gas density, andalso the index of refraction. The total uncertainty in the referencevelocity was estimated at ±0.6%.

In the prototype the cylindrical lens in the optical delivery system wasnot insensitive to the index of refraction of the surrounding gas.Therefore as the refractive index of the gas increased with pressure,the spacing of the two sheets of light increased slightly. An opticaldesign program was used to determine the necessary correction in beamspacing relative to the measured spacing in atmospheric air. For thesetests a 5.8% correction was required and applied. Note that acylindrical lens doublet designed using the same principle as thecollection lens doublet would not require any such correction to thebeam spacing measurement that is used in the velocity calculations.

FIG. 7 shows the data obtained over a two-day period of testing. In FIG.7 each point is a data point for one velocity measurement. The ordinate(Y axis) shows the deviation of the optical measurement from thereference orifice meter. FIG. 7 shows good overall agreement for thevelocities obtained using the reference system and the optical flowmeter of the present invention.

What is claimed is:
 1. An optical device that generates a signal whichdescribes fluid flow on the basis of the motion of particles suspendedin a fluid flowing through a pressurized pipe, said optical devicecomprising: (a) a narrow frequency light source; (b) an optical deliverysystem coupled to said light source, said optical delivery systemincluding multiple optical components mounted completely within thepressurized environment of the pipe and producing at least two lightbeams within the interior of the pipe; (c) a collector that mountscompletely within the pressurized environment of the pipe and whichreceives light scattered by said particles from said at least two beams;(d) a photo detector coupled to said collector, said photo detectorconverting said scattered light received by said collector into anelectrical signal; and (e) a pressure fitting that permits opticalaccess into the pressurized environment of the pipe.
 2. The deviceaccording to claim 1, wherein said narrow frequency light sourcecomprises a laser.
 3. The device according to claim 2, wherein saidoptical components include: (i) a collimator; (ii) a light splitter, and(iii) a focusing lens, which are located inside the pressurizedenvironment of the pipe.
 4. The device according to claim 1, furthercomprising a rigid structure, with a circular aperture, located betweentwo sections of pipe, and wherein said optical delivery system and saidcollector are mounted in said rigid structure permitting direct opticalaccess to the interior of the pipe.
 5. The device according to claim 1,wherein multiple measurement locations are distributed within the pipecross section, by using one or more sets of optical collectors andoptical delivery systems.
 6. The device according to claim 5, whereinone of said measurements is located at the center of the pipe crosssection.
 7. The device according to claim 5 wherein said measurementlocations are distributed symmetrically about the longitudinal axis ofthe pipe.
 8. The device according to claim 5 wherein said measurementlocations are distributed within the pipe cross section by using atleast one holographic optical element or at least one manufactureddiffractive optical element.
 9. The device according to claim 4 whereinsaid optical access into and out of said rigid structure is via at leastone optical fiber passing through the body of said rigid structure. 10.The device as in claim 1, further comprising an optical fiber couplingsaid photo detector to said collector, wherein said photo detector islocated outside of said pressurized environment, and said optical fiberextends through the pressure fitting.
 11. The device as in claim 10,further comprising an optical fiber coupling said light source to saidoptical delivery system, and wherein said light source is locatedoutside of said pressurized environment, and said optical fiber extendsthrough a pressure fitting.
 12. The device as in claim 1, wherein saidat least two light beams are aligned in parallel.
 13. The device as inclaim 1, wherein said optical delivery system and said collector arelocated outside the internal diameter of the pipe to minimize thedisruption of fluid flow within the pressurized pipe.
 14. A device thatgenerates a signal which describes fluid flow on the basis of the motionof particles suspended in a fluid flowing through a pressuized pipe,said device comprising: (a) a light source; (b) an optical deliverysystem counted to said light source, said optical delivery systemproducing at least two substantially parallel light beams within theinterior of the pipe; (c) a collector lens which receives lightscattered by said particles from said at least two beams; (d) a photodetector which couples to said collector lens, said photo detectorconverting said scattered light received by said collector lens into anelectrical signal, and (e) an optical fiber coupling said photo detectorto said collector lens, and wherein said collector lens is mountedcompletely within, and directly exposed to, the pressurized environmentof said pipe, and said photo detector is located outside of saidpressurized environment, and said optical fiber extends through apressure fitting.
 15. The device according to claim 14, wherein saidlight source comprises a laser.
 16. The device according to claim 15,wherein said optical delivery system comprises a light splitter and afocusing lens, which are located within the pressurized environment ofthe pipe.
 17. The device according to claim 16, wherein said opticaldelivery system and said collector lens are mounted in a rigid structurethat includes a passageway through which the fluid flows.
 18. A processfor determining the velocity of a fluid moving through a pipe comprisingconverting the electrical signals generated by the device according toclaim 14 comprising: (a) digitizing each pulse of the detector outputsignal caused by collected light scattered from a particle passingthrough a light beam exceeding a threshold above the ambient noise anddetermining its temporal centroid; (b) calculating the differencebetween the temporal centroid of each pulse that could have originatedon the downstream beam of light to the temporal centroids of the pulsesthat could have occurred on the upstream beam in the recent past toobtain all the possible transit times of a particle from one beam oflight to another; (c) converting each possible transit time to a transitvelocity, by dividing the distance between the beams by the transit timeand recording the transit velocities in a corrologram; (d) identifyingthe peak in the corrologram generated over a finite time period by thelarge number of transit velocities clustered at a specific velocity; and(e) averaging transit velocities within that cluster in the corrologram.19. The device according to clalm 14, wherein multiple measurementlocations are distributed within the pipe cross section by using one ormore sets of optical collectors and optical delivery systems.
 20. Thedevice according to claim 19, wherein one of said measurements islocated at the center of the pipe cross section.
 21. The deviceaccording to claim 19 wherein said measurement locations are distributedsvmmetrically about the longitudinal axis of the pipe.
 22. The deviceaccording to claim 19 wherein said multiple measurement locations aredistributed within the pipe cross section by using at least onemanufactured diffractive optical element or at least one hologaphicoptical element.
 23. The device of claim 17, wherein said structure ispositioned between two adjacent sections of pipe to permit directoptical access to the interior of the pipe, while maintaining thepressure within said pipe.
 24. The device as in claim 14, wherein saidoptical delivery system is immersed in the fluid within said pipeline.25. The device as in claim 24, wherein said optical delivery system andsaid collector are positioned outside the flow path of the fluid in thepipeline.
 26. The device as in claim 14, wherein said collector lens islocated outside the internal diameter of the pipe to minimize thedisruption of fluid flow within the pressurized pipe.
 27. A device formeasuring the direction and flow of fluid through a pipe based on themotion of particles suspended in the fluid comprising: (a) a narrowfrequency light source; (b) an optical delivery system optically coupledto said light source that produces at least two light beams within theinterior of the pipe; (c) a collector which focuses light scattered bysaid particles from said at least two beams; (d) a photo detector whichconverts said scattered light focused by said collector into anelectrical signal; and (e) an optical fiber which communicates betweensaid collector and said photo detector, wherein said optical deliverysystem and said collector are mounted in a structure that includes apassageway through which the fluid flows, to permit direct opticalaccess to the interior of the pipe.
 28. The device according to claim27, wherein said narrow frequency light source is a laser.
 29. By Thedevice according to claim 27, wherein said optical delivery systemfurther comprises one or more of the following optical elements: (i) acollimator; (ii) a light splitter; or (iii) a mirror.
 30. The deviceaccording to claim 27, wherein said structure is inserted between twosections of pipe such that said optical delivery system and saidcollector are located within the pressurized environment of the pipe.31. The device according to claim 27, wherein multiple measurementlocations are distributed within the pipe cross section, by using one ormore sets of optical collectors and optical delivery systems.
 32. Thedevice according to claim 31 wherein one of said measurements is locatedat the center of the pipe cross section.
 33. The device according toclaim 31 wherein said multiple measurement locations are distributedsymetrically about the longitudinal axis of the pipe.
 34. The deviceaccording to claim 31 wherein said multiple measurement locations aredistributed within the pipe cross section by using at least onemanufactured diffractive optical element or at least one holographicoptical element.
 35. The device as in claim 27, wherein said at leasttwo light beams are aligned in parallel.
 36. The device as in claim 27,wherein said optical delivery system and said collector are immersed inthe fluid within said pipeline.
 37. The device as in claim 36, whereinsaid pipe is pressurized and said optical delivery system and saidcollector are mounted within the pressurized interior of the pipe. 38.The device as in claimi 37, wherein said optical delivery system andsaid collector are positioned outside the flow path of the fluid in thepipeline.
 39. The device as in claim 27, wherein said passageway has aninternal diameter that is equal to or greater than the inside diameterof said pipe.
 40. The device as in claim 39, wherein said opticaldelivery system and said collector are mounted in said structure in alocation outside the inside diameter of said pipe to minimize disruptionof fluid flow within the pipe.
 41. The device as in claim 27, whereinsaid collector comprises a lens with a first surface and a last surface,with said first surface on the side of the lens nearest the scatteredlight, and the last surface on the side of the lens nearest the photodetector, and wherein said first surface has a spherically concave shapeso that the light scattered by the particles located at the point inspace where the measurement is to be taken strikes the first surfacesubstantially perpendicularly.
 42. An optical device that generates asignal which describes fluid flow on the basis of the motion ofparticles suspended in a fluid flowing through a pressurized pipe, saidoptical device comprising: (a) a narrow fequency light source; (b) anoptical delivery system coupled to said light source, said opticaldelivery system being mounted completely within the pressurizedenvironment of the pipe and producing at least two light beams withinthe interior of the pipe; (c) a collector that mounts completely withinthe pressurized environment of the pipe and which receives lightscattered by said particles from said at least two beams; and (d) aphoto detector coupled to said collector, said photo detector convertingsaid scattered liaht received by said collector into an electricalsignal; and wherein said collector comprises a lens with a first surfaceand a last surface, with said first surface on the side of the lensnearest the scattered light, and the last surface on the side of thelens nearest the photo detector, and wherein said first surface has aspherically concave shape so that the light scattered by the particleslocated at the point in space where the measurement is to be takenstrikes the first surface substantially perpendicularly.
 43. An opticaldevice that generates a signal which describes fluid flow on the basisof the motion of particles suspended in a fluid flowing through apressurized pipe, said optical device comprising: (a) a light source;(b) an optical delivery system coupled to said light source, saidoptical delivery system producing at least two substantially parallellight beams within the interior of the pipe; (c) a collector lens whichreceives light scattered by said particles from said at least two beams;and (d) a photo detector which couples to said collector lens, saidphoto detector converting said scattercd light received by saidcollector lens into an electrical signal, and wherein said collectorlens is completely mounted within, and directly exposed to, thepressurized environnent of said pipe; and wherein said collector lenshas a first surface and a last surface, with said first surface on theside of the collector lens nearest the scattered light, and the lastsurface on the side of the collector lens nearest the photo detector,and wherein said fast surface has a spherically concave shape so thatthe light scattered by the particles located at the point in space wherethe measurement is to be taken strikes the first surface substantiallyperpendicularly.